Torque transfer unit with integrated electric drive motor

ABSTRACT

An axle assembly comprises a power transmission device including a housing having a cylindrically shaped sidewall. The power transmission device selectively communicates rotatable motion from an input member to an output member. A frictional clutch is disposed in the housing and includes a drum. A first and a second axle shaft selectively drive a first and a second drive wheel, respectively. A differential selectively transfers drive torque from the output member to at least one of the first and second axle shafts. An electric motor comprising a coil and a plurality of magnets is provided on the axle assembly. In one example, the coil is disposed on the housing and the magnets are disposed on the drum. The coil is configured to selectively energize to provide one of a positive or negative torque input to the output member.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No. 13/050,001 filed Mar. 17, 2011 (now U.S. Pat. No. 8,597,145 issued Dec. 3, 2013), the disclosure of which is incorporated by reference as if set forth herein in its entirety.

FIELD

The present disclosure relates generally to a torque transfer unit with an integrated electric drive motor.

BACKGROUND

This section provides background information related to the present disclosure which is not necessarily prior art.

Due to increased demand for four-wheel drive and all-wheel drive vehicles, many power transmission systems are being incorporated into vehicle driveline applications for transferring drive torque to the wheels. Many vehicles include a power transmission device operably installed between the primary and secondary drivelines. Such power transmission devices are typically equipped with a torque transfer mechanism for selectively transferring drive torque from the primary driveline to the secondary driveline to establish a four-wheel drive mode of operation.

Some power transmission devices are operable for automatically directing drive torque to the secondary wheels without any input or action on the part of the vehicle operator. When traction is lost at the primary wheels, a clutch is actuated for transferring torque to the secondary wheels to establish the four-wheel drive mode. Some power transmission devices are equipped with an electrically-controlled clutch actuator operable to regulate the amount of drive torque transferred across the clutch to the secondary driveline as a function of changes in vehicle operating characteristics such as vehicle speed, throttle position, and steering angle. While many power transmission devices are currently used in four-wheel drive vehicles, a need exists to advance the technology.

SUMMARY

This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

An axle assembly comprises a power transmission device including a housing. In some examples, the housing can have a cylindrically shaped sidewall. The power transmission device selectively communicates rotatable motion from an input member to an output member. A friction clutch is disposed in the housing and can be actuated to selectively transfer torque between the input member and the output member. The friction clutch includes a first clutch member and a second clutch member. The first clutch member is operatively coupled to the input member while the second clutch member is operatively coupled to the output member. First and second axle shafts drive first and second drive wheels, respectively. A differential transfers drive torque from the output member to at least one of the first and second axle shafts. An electric motor comprising a coil and a plurality of magnets is provided on the axle assembly. In one example, the coil is disposed on the housing and the magnets are disposed on the second clutch member. The coil can be selectively energized to provide one of a positive or negative torque input to the output member.

According to other features, the first and second axle shafts are rear axle shafts. The coil is arranged on the cylindrically shaped sidewall of the housing. The first clutch member is a clutch hub and the second clutch member is a cylindrical clutch drum. The magnets are disposed on an outer cylindrical surface of the drum. The frictional clutch is a wet clutch.

According to other features, the power transmission device is configured to operate in various drive modes. For example, the power transmission device can operate in an electric motor assist drive mode wherein the electric motor is energized and provides either a positive or negative torque to the output shaft. The power transmission device is further configured to operate in an electric drive mode wherein the friction clutch of the power transmission device is not coupled and wherein the electric motor is energized and provides a sole torque input to the output shaft. The power transmission device is further configured to operate in a regenerative drive mode wherein the electric motor provides a braking input to the power transmission device and wherein the braking input provides a regenerative input to a battery. According to one example, the differential is a rear differential.

Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

The present invention will become more fully understood from the detailed description and the accompanying drawings wherein:

FIG. 1 is a cross-sectional side view of a power transmission device incorporating an electric motor and constructed in accordance to one example of the present teachings;

FIG. 2 is a schematic of a four-wheel drive vehicle equipped with the power transmission device of FIG. 1 and shown in a first drive mode;

FIG. 3 is a schematic of a four-wheel drive vehicle equipped with the power transmission device of FIG. 1 and shown in a second drive mode;

FIG. 4 is a schematic of a four-wheel drive vehicle equipped with the power transmission device of FIG. 1 and shown in a third drive mode;

FIG. 5 is a schematic of a four-wheel drive vehicle equipped with the power transmission device of FIG. 1 and shown in a fourth drive mode;

FIG. 6 is a schematic view of a four-wheel drive vehicle equipped with the power transmission device of FIG. 1 and shown in a fifth drive mode; and

FIG. 7 is a cross-sectional side view of a power transmission device incorporating an electric motor constructed in accordance to other features of the present teachings.

Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION

Example embodiments will now be described more fully with reference to the accompanying drawings. The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.

The present invention is directed to an axle assembly including a torque transfer unit or power transmission device that may be adaptively controlled for modulating the torque transferred between a rotatable input member and a rotatable output member. The power transfer device may be useful within motor vehicle drivelines as a stand-alone device that may be easily incorporated between sections of propeller shafts, directly coupled to a drive axle assembly, or other in-line torque coupling applications. Accordingly, while the present invention is hereinafter described in association with a specific structural embodiment for use in a driveline application, it should be understood that the arrangement shown and described is merely intended to illustrate an exemplary embodiment of the present invention.

With initial reference to FIGS. 1 and 2 of the drawings, a drive train 10 for a four-wheel vehicle is shown. Drive train 10 includes a first axle assembly 12, a second axle assembly 14, and a powertrain assembly 16 for generating and delivering drive torque to the axle assemblies 12 and 14, respectively. In the particular arrangement shown, the first axle assembly 12 is the front axle while the second axle assembly 14 is the rear axle. The powertrain assembly 16 includes an engine 18 and a multi-speed transmission 20 having an integrated front differential unit 22 for driving front wheels 24 via front axle shafts 26. The powertrain assembly 16 further includes a transfer unit 28 driven by the transmission 20 for delivering torque to an input member 29 of a torque transfer unit or power transmission device 30 via a drive shaft assembly 32. The input member 29 of the power transmission device 30 is coupled to the drive shaft assembly 32 while its output member 31 is arranged to drive a rear differential 36. The second axle assembly 14 also includes a pair of rear wheels 38 that are connected to the rear differential 36 via rear axle shafts 40.

The drive train 10 is shown to include an electronically-controlled power transfer system 42 that includes the power transmission device 30. The power transfer system 42 is operable to selectively provide drive torque in a two-wheel drive mode or a four-wheel drive mode. In the two-wheel drive mode, torque is not transferred via the power transmission device 30. Accordingly, 100% of the drive torque delivered by the transmission 20 is provided to the front wheels 24. In the four-wheel drive mode, power is transferred through the power transmission device 30 to supply drive torque to the rear wheels 38. The power transfer system 42 further includes a controller 50 that is in communication with vehicle sensors 52 for detecting dynamic and operational characteristics of the motor vehicle. The vehicle sensors 52 can include, but are not limited to, sensors that can determine wheel speed, wheel slip, steering wheel angle, yaw rate, throttle position, engine/transmission torque, vehicle speed, stability control status, etc.

The controller 50 is operable to control actuation of the power transmission device 30 in response to signals from the vehicle sensors 52. The controller 50 may be programmed with a predetermined target torque split between the first and the second set of wheels 24 and 38, respectively. Alternatively, the controller 50 may function to determine the desired torque to be transferred through the power transmission device 30 via other methods. Regardless of the method used for determining the magnitude of torque to transfer, the controller 50 operates the power transmission device 30 to maintain the desired torque magnitude. As will become further appreciated from the following discussion, the controller 50 may also communicate with an electric motor 56 that is arranged on the power transmission device 30 for providing positive or negative torque in various drive modes to assist in vehicle operation.

With specific attention now to FIG. 1, the power transmission device 30 will be described in greater detail. The input member 29 is shown to include an input shaft 70 while the output member 31 is shown to include an output shaft 72. The output shaft 72 is preferably a pinion shaft having a pinion meshed with a ring gear on the rear differential 36. The power transmission device 30 also includes a friction clutch 74 that is operably dispersed between the input shaft 70 and the output shaft 72. The power transmission device 30 also includes a housing assembly 75 that comprises a front housing 76 and a substantially cup-shaped rear housing 78. The rear housing 78 can be supported on an axle carrier 80. The rear housing 78 includes a generally cylindrically shaped side wall 82 that has an inner circumferential surface 84. The input shaft 70 is supported in the front housing 76 by a bearing 86. The output shaft 72 is received by a tubular output spindle 88 that is supported in the rear housing 78 by bearings 90 and 91.

The input shaft 70 includes a raised splined portion 92 defining a clutch hub 94. A set of inner friction plates 96 are drivingly coupled to the clutch hub 94 via a splined engagement. The inner friction plates 96 are interleaved with a plurality of outer friction plates 98. The outer friction plates 98 are in splined engagement with a clutch drum 100. The drum 100 is generally cylindrically shaped and defines an inner cavity 102 within which the interleaved friction plates are located. The drum 100 further includes an outer circumferential surface 103. The outer circumferential surface 103 opposes the inner circumferential surface 84 of the side wall 82. The drum 100 is drivingly coupled to a radial flange portion of the output spindle 88. The output spindle 88 is coupled for rotation with the output shaft 72 via another splined interface. In the embodiment depicted, the friction clutch 74 is a wet clutch. Accordingly, clutch fluid is contained within the cavity 102 defined by the drum 100 and is in communication with the friction plates 96 and 98. Fluid is also contained within the housing assembly 75.

A piston 104 is slidably positioned within a cavity 106 that is formed within the housing assembly 75. The piston 104 is axially movable into engagement with a thrust bearing 108 and an apply plate 110. Pressurized fluid can flow through a conduit 112 formed in the front housing 76 and act on a front face 114 of the piston 104. Other configurations are contemplated. When pressurized fluid builds on the face 114 of the piston 104, the piston 104 translates and applies a force through the thrust bearing 108 and the apply plate 110 to the plurality of interleaved clutch plates 96 and 98. Torque is transferred between the input shaft 70 and the output shaft 72 via the components previously described when the friction plates 96 and 98 are forced into contact with one another. A hydraulic powerpack 116 is schematically shown in FIGS. 1 and 2 and is arranged to provide a controllable source of pressurized fluid to conduit 112. Regulation of the fluid pressure in conduit 112 acts to proportionally regulate the clutch engagement force applied by piston 104 to apply plate 110 which, in turn, regulates the drive torque transferred from input shaft 70 to output shaft 72. Controller 50 is shown to communicate with hydraulic powerpack 116 and is operable to control the fluid pressure generated by the hydraulic powerpack 116. While not limited thereto, the powerpack 116 can include a motor-driven fluid pump and valving for controlling the fluid pressure delivered to conduit 112.

The electric motor 56 generally includes a plurality of magnets 120 and a coil 122. In the example shown, the magnets 120 are fixedly mounted on the outer circumferential surface 103 of the drum 100 for concurrent rotation therewith. The magnets 120 can be a plurality of magnets arranged around the outer circumferential surface 130 of the drum 100. In this regard, the magnets 120 can use the drum 100 as a rotor. The coil 122 is fixedly mounted onto the inner circumferential surface 84 of the rear housing 78. The electric motor 56 can therefore occupy a space defined by an annular pocket 126 defined generally between the cylindrically shaped side wall 82 of the rear housing 78 and the outer circumferential surface of the drum 100. The electric motor 56 can receive power from an on-board battery source 130 and/or other power sources such as the vehicle's alternator. The coil 122 can be energized to cause the magnets 120 and therefore the drum 100 to rotate in a first direction that corresponds to a forward rotation of the drive axle 14 or a second direction that corresponds to a reverse rotation of the drive axle 14. It is appreciated that in some examples, as described herein, the resultant torque input from the electric motor 56 can supplement (positively or negatively) the drive torque already supplied by the engine 18 through the input shaft 70.

As will be described in the following discussion directed towards FIGS. 2-6, the electric motor 56 adds functionality to the power transmission device 30 and can be active or inactive in various drive modes. In this regard, the controller 50 can, in addition to controlling actuation of the friction clutch 74, send a signal to the electric motor 56 to activate and deactivate the electric motor 56 according to various inputs from the vehicle sensors 52. It is contemplated that the controller 50 can be configured to automatically activate and deactivate the electric motor 56 based on driving conditions or alternatively from a driver initiated input (i.e., drive mode selector switch, etc.).

As shown in FIG. 2, the power transmission device 30 is decoupled to define a first drive mode. More specifically, the friction clutch 74 is not engaged. In this regard, drive torque is not transmitted from the input shaft 70 to the output shaft 72. In addition, the electric motor 56 is inactive. With the power transmission device 30 operating in the first drive mode, the drive train 10 operates in a front wheel drive mode such that power is communicated only to the front wheels 24 via the powertrain 16.

Turning now to FIG. 3, the power transmission device 30 is shown in a second drive mode. In the second drive mode, the friction clutch 74 of the power transmission device 30 is at least partially engaged such that drive torque is transferred from the input shaft 70 to the output shaft 72 to provide power to the rear wheels 38 through the rear differential 36. In the second drive mode, the drive train 10 is operating in a conventional on-demand all wheel drive mode. In the second mode as illustrated in FIG. 3, the electric motor 56 is inactive.

Turning now to FIG. 4, the power transmission device 30 is shown operating in a third or electric motor assist drive mode. In the third drive mode, the friction clutch 74 is at least partially engaged such that torque is transferred from the input shaft 70 to the output shaft 72 such that the drive train 10 is operating in a conventional on-demand all wheel drive mode. In the third drive mode as shown in FIG. 4, the electric motor 56 is also active. The electric motor 56 can provide a positive torque input to the drum 100 resulting in an increase in net drive torque being transferred to the output shaft 72. In some circumstances, the electric motor 56 can alternatively provide a negative torque onto the drum 100 such that a reduced output torque is transferred to the output shaft 72. In either scenario, the controller 50 can communicate a signal to the electric motor 56 that corresponds with the desired positive or negative torque input.

With reference now to FIG. 5, the power transmission device 30 is shown in a fourth or electric drive mode. In the fourth drive mode, the power transmission device 30 is inactive such that the friction clutch 74 is not engaged and drive torque is not communicated from the input shaft 70 to the output shaft 72. However, in the fourth drive mode, drive torque can be communicated to the output shaft 72 solely from the electric motor 56. In this regard, in the fourth drive mode, the controller 50 can operate the power transmission device 30 in an electric on-demand all wheel drive mode where the front wheels 24 are provided drive torque from the engine 18 while the rear wheels 38 are provided drive torque solely through the electric motor 56. Additionally, in the fourth drive mode, the controller 50 can operate the drive train 10 such that the only wheels being supplied with drive power are the rear wheels 38 that are powered solely from the electric motor 56.

With reference now to FIG. 6, the power transmission device 30 is shown operating in a fifth or regenerative drive mode. In the fifth drive mode, the friction clutch 72 is disengaged such that drive torque is not transmitted from the input shaft 70 to the output shaft 72. In the fifth drive mode, the electric motor 56 can be used in a battery charge, regenerative mode. In this regard, the electric motor 56 can be used at higher vehicle speeds for braking while utilizing the braking input as a regenerative input to the battery 130. Additionally or alternatively, the electric motor 56 can be used at low vehicle speeds such as to maintain a vehicle speed.

With reference now to FIG. 7, a power transmission device 230 constructed in accordance to additional features of the present teachings is shown. The power transmission device 230 includes similar features as discussed above with respect to the power transmission device 30. In this regard, similar components are identified with reference numerals increased by 200.

The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure. 

1. A torque transfer device comprising: a first housing; a second housing mounted to the first housing, the first and second housings cooperating to define a cavity; a first shaft received in the first housing and extending into the cavity; a plurality of first clutch plates received in the cavity and non-rotatably coupled to the first shaft; a second shaft received in the second housing; an outer clutch drum mounted on the second shaft, the outer clutch drum being received in the cavity and disposed about the first shaft; a plurality of second clutch plates received in the cavity and non-rotatably coupled to the outer clutch drum, the second clutch plates being interleaved with the first clutch plates to form a clutch pack; a first bearing mounted to the first shaft and the first housing, the first bearing supporting the first shaft for rotation relative to the first housing, the first bearing being disposed on a first side of the clutch pack; a second bearing mounted to the outer clutch drum and the second housing, the second bearing supporting the outer clutch drum for rotation relative to the second housing, the second bearing being disposed on a second side of the clutch pack such that the clutch pack is disposed axially along a rotational axis of the first and second shafts between the first and second bearings; an actuator configured to compress the clutch pack against the outer clutch drum to permit rotary power to be transmitted between the first and second shafts; and an electric motor having a stator and an armature, the stator being fixedly coupled to the first and second housings and received in the cavity, the armature being coupled to the outer clutch drum for common rotation.
 2. The torque transfer device of claim 1, wherein the actuator is a hydraulic actuator.
 3. The torque transfer device of claim 2, wherein the first housing defines a piston chamber and wherein the actuator comprises a piston that is received in the piston chamber.
 4. The torque transfer device of claim 1, wherein the outer clutch drum is supported by a third bearing that is disposed between the first shaft and the outer clutch drum.
 5. The torque transfer device of claim 4, wherein the outer clutch drum comprises a cylindrical projection that is received into an aperture formed in the first shaft.
 6. The torque transfer device of claim 1, further comprising a lubricating oil that is received in the cavity.
 7. The torque transfer device of claim 1, wherein the actuator comprises an apply plate, which is abutted directly against the clutch pack.
 8. The torque transfer device of claim 7, wherein the actuator further comprises a thrust bearing that is abutted directly against the apply plate on a side of the apply plate that is opposite the clutch pack.
 9. A torque transfer device comprising: a housing assembly defining a cavity; a first shaft received in the housing assembly and extending into the cavity; a plurality of first clutch plates received in the cavity and non-rotatably coupled to the first shaft; a second shaft received in the housing assembly, the second shaft being a pinion shaft that is adapted to drive a pinion that is meshed with a ring gear of a differential mechanism; an outer clutch drum mounted on the second shaft, the outer clutch drum being received in the cavity and disposed about the first shaft; a plurality of second clutch plates received in the cavity and non-rotatably coupled to the outer clutch drum, the second clutch plates being interleaved with the first clutch plates to form a clutch pack; an actuator configured to compress the clutch pack against the outer clutch drum to permit rotary power to be transmitted between the first and second shafts; and an electric motor having a stator and an armature, the stator being fixedly coupled to the housing assembly and received in the cavity, the armature being coupled to the outer clutch drum for common rotation.
 10. The torque transfer device of claim 9, wherein the actuator is a hydraulic actuator.
 11. The torque transfer device of claim 10, wherein the housing assembly defines a piston chamber and wherein the actuator comprises a piston that is received in the piston chamber.
 12. The torque transfer device of claim 9, wherein the outer clutch drum is supported on a bearing that is disposed between the first shaft and the outer clutch drum.
 13. The torque transfer device of claim 12, wherein the outer clutch drum comprises a cylindrical projection that is received into an aperture formed in the first shaft.
 14. The torque transfer device of claim 9, further comprising a lubricating oil that is received in the cavity.
 15. The torque transfer device of claim 9, wherein the actuator comprises an apply plate, which is abutted directly against the clutch pack.
 16. The torque transfer device of claim 15, wherein the actuator further comprises a thrust bearing that is abutted directly against the apply plate on a side of the apply plate that is opposite the clutch pack. 